Silicone rubber foam brush

ABSTRACT

A method and device for cleaning and pretreating solar panels is provided. The device comprises a brush having cleaning elements made from silicone foam rubber material. The cleaning elements can be flaps of silicone foam rubber material. A sheet of silicone foam rubber material having two free ends can be attached to a core member such that the two free ends extend away from the core member to form flaps. The solar panels can be cleaned by brushing the solar panel surfaces with the flaps of silicone foam rubber material. The solar panels can also be pretreated by brushing the solar panel surfaces with silicone foam rubber material.

CROSS REFERENCE TO RELATED APPLICATIONS

This patent application claims the benefit of priority under 35 U.S.C.Section 119(e) from U.S. Provisional Application Ser. No. 62/303,958,filed on Mar. 4, 2016 and titled “Silicone Rubber Foam Brush,” which ishereby incorporated by reference as if set forth in its entirety herein.

FIELD OF THE INVENTION

The present invention generally relates to brush elements, and moreparticularly, to silicone foam rubber brushes.

BACKGROUND OF THE INVENTION

Cleaning brushes of various designs have been used for a variety ofindustrial, commercial and consumer applications. Typical synthetic foammaterials have been used in certain cleaning applications, for example,cleaning cars. These synthetic foam materials provide a benefit overnon-woven materials in that they don't absorb water. In addition, thesesynthetic foam materials also resist dirt and debris accumulating andremaining in the material. Dirt and debris that is maintained in thecleaning material can scratch the cleaning surface when the dirtimpregnated material is brought into contact with the cleaning surfaceduring subsequent cleaning operations. Despite the benefits provided bytypical synthetic foam materials, improved cleaning performance isdesirable.

The present invention addresses these and other limitations associatedwith cleaning brushes.

SUMMARY OF THE INVENTION

According to an aspect of the invention, a method of performing at leastone of a cleaning, buffing, and polishing action on a surface of a solarpanel is provided. The method includes the steps of providing a coremember and providing at least one sheet of material. The at least onesheet of material is comprised of closed-cell silicone foam rubber andhas a first free end portion. The at least one sheet of material isattached to the core member with the first free end portion extendingaway from the core member. The method includes the step of causing thecore member to move in a first direction such that a portion of the atleast one sheet of material is brought into contact with the surface ofthe solar panel in a repeating pattern. The method further includes thestep of causing the core member to move in a second direction such thatthe core member moves along an area of the solar panel so as to performthe at least one of a cleaning, buffing, and polishing.

In accordance with a further aspect, the method further includes thestep of providing a flexible structural element disposed adjacent atrailing side of the at least one sheet of material, wherein theflexible structural element is configured to increase a pressure betweenthe at least one sheet of material and the surface during the contact.

In accordance with yet further aspect, the first direction is arotational direction and wherein the second direction is a translationaldirection.

In accordance with a further aspect, a light transmission characteristicof the solar panel is improved.

In accordance with still further aspect, the at least one sheet ofmaterial includes a second free end portion and a middle sectiondisposed between the first and second free end portions, and wherein atleast a portion of the middle section is attached to the core member andthe first and second free end portions extend away from the core member.

In accordance with a further aspect, the core member includes a flatsurface adjacent the attachment of each said sheet of material.

In accordance with another aspect, a method of performing at least oneof a cleaning, buffing, and polishing action on a surface, withoutrequiring water, is provided. The method comprises the steps ofproviding a core member and providing at least one sheet of material.The at least one sheet of material is comprised of closed-cell siliconefoam rubber and has a first free end portion. The at least one sheet ofmaterial is attached to the core member with the first free end portionextending away from the core member. The method includes the step ofcausing the core member to move in a first direction such that a portionof the at least one sheet of material is brought into sliding contactwith the surface in a repeating pattern. The sliding contact between theat least one sheet of material and the surface occurs under a pressureand relative velocity sufficient to generate a force that results in atleast one of a cleaning, buffing, and polishing.

In accordance with a further aspect, the first direction is a rotationaldirection.

In accordance with a still further aspect, the second direction is atranslational direction.

In accordance with a yet further aspect, the method includes the step ofproviding a flexible structural element disposed adjacent a trailingside of the at least one sheet of material wherein the flexiblestructural element is configured to increase the pressure between the atleast one sheet of material and the surface during the sliding contact.

In accordance with a further aspect, the surface is a solar panel and alight transmission characteristic of the solar panel is improved.

In accordance with a still further aspect, the at least one sheet ofmaterial includes a second free end portion and a middle sectiondisposed between the first and second free end portions, and wherein atleast a portion of the middle section is attached to the core member andthe first and second free end portions extend away from the core member.

In accordance with another further aspect, the wherein the core memberincludes a flat surface adjacent the attachment of each said sheet ofmaterial.

In accordance with another aspect, a brush configured to perform atleast one of a cleaning, buffing, and polishing action on a surface isprovided. The brush includes a core member having a central axis and aperiphery. The brush includes at least one sheet of material comprisedof closed-cell silicone foam rubber and has at least a first free endportion. The at least one sheet of material is attached to the coremember with the at least first free end portion extending away from theperiphery of the core member such that the material attachment issubstantially parallel to the central axis of the core member. The coremember includes a flat surface adjacent the attachment of each saidsheet of material. The core member and the at least one sheet ofmaterial are configured for relative movement with respect to thesurface in at least a first direction. The motion in the first directioncauses the at least first free end portion of the at least one sheet ofmaterial to contact the surface at a non-zero velocity and the motion ofthe at least first free end portion of the at least one sheet ofmaterial produces at least one of the cleaning, buffing and/or polishingaction on the surface.

In accordance with a further aspect, the core member defines asubstantially cylindrical member having curved portions adjacent eachflat surface.

In accordance with a still further aspect, the core member has arigidity in excess of the rigidity of the at least one sheet ofmaterial.

In accordance with another further aspect, the core member is configuredfor relative movement in the first direction such that the core memberis configured to move and the surface is substantially stationary.

In accordance with a yet further aspect, the core member is configuredfor relative movement in the first direction such that the core memberis configured to remain substantially stationary relative to a movingsurface.

In accordance with a further aspect, the first direction of movement ofthe core member is translational movement.

In accordance with another further aspect, the first direction ofmovement of the core member is rotational movement.

In accordance with a still further aspect, the core member, and the atleast one sheet of material, are configured for movement in at least asecond direction.

In accordance with a yet further aspect, the second direction ofmovement is rotational about the central axis of the core member.

In accordance with a further aspect, the at least one sheet of materialincludes a second free end portion and a middle section disposed betweenthe first and second free end portions, and wherein at least a portionof the middle section is attached to the core member and the first andsecond free end portions extend away from the periphery of the coremember.

In accordance with a still further aspect, the middle section of the atleast one sheet of material includes first and second portions, and thefirst portion of the middle section is attached to the core member at afirst location and the second portion of the middle section is attachedto the core member at a second location.

In accordance with a yet further aspect, a third portion of the middlesection of the at least one sheet of material is disposed between thefirst and second portions, and wherein the third portion extends about aperiphery of the core member between the first and second locations.

In accordance with a further aspect, the core member includes at leastone c-channel groove and the at least one sheet of material is attachedto the core member via the c-channel groove.

In accordance with a still further aspect, the at least one sheet ofmaterial includes a second free end portion and a middle sectiondisposed between the first and second free end portions, and wherein atleast a portion of the middle section is retained in the c-channelgroove.

In accordance with a yet further aspect, the brush includes at least onesecurement rod, wherein the rod is disposed within the c-channel grooveto retain the middle section of the sheet of material within thec-channel groove.

In accordance with a yet further aspect, the brush includes at least onesecurement coil, wherein the coil is disposed within the c-channelgroove to retain the middle section of the sheet of material within thec-channel groove.

In accordance with another aspect, a method of pretreating a surface ofa solar panel is provided. The method includes the steps of providing abrush having closed-cell silicone foam rubber flaps and brushing thesurface using the brush until an increase of performance of the solarpanel is achieved.

In accordance with a further aspect, the solar panel is exposed toapproximately 7,000 brushing cycles.

In accordance with another aspect, a method of performing at least oneof a cleaning, buffing, and polishing action on a surface of a solarpanel is provided. The method includes the steps of providing first andsecond supports and providing a belt. The belt is comprised ofclosed-cell silicone foam rubber and the belt extends about the firstand second supports. The method includes the step of causing thesupports to rotate such that a portion of the belt is brought intosliding contact with the solar panel in a repeating pattern. The slidingcontact between the belt and the solar panel occurs under a pressure andrelative velocity sufficient to generate a force that results in atleast one of a cleaning, buffing, and polishing.

In accordance with a further aspect, a light transmission characteristicof the solar panel is improved.

In accordance with another aspect, a method of performing at least oneof a cleaning, buffing, and polishing action on a surface of a solarpanel is provided. The method includes the steps of providing a backerplate and providing a pad. The pad is comprised of closed-cell siliconefoam rubber and is attached to the backer plate. The method includes thestep of causing the backer plate to move such that a portion of the padis brought into sliding contact with the solar panel in a repeatingpattern. The sliding contact between the pad and the solar panel occursunder a pressure and relative velocity sufficient to generate a forcethat results in at least one of a cleaning, buffing, and polishing.

In accordance with a further aspect, a light transmission characteristicof the solar panel is improved.

In accordance with another aspect, a surface treatment tool configuredto perform at least one of a cleaning, buffing, and polishing action ona solar panel surface is provided. The tool includes first and secondsupports and a belt. The belt is comprised of closed-cell silicone foamrubber and the belt extends about the first and second supports. Thesupports are configured to rotate such that a portion of the belt isbrought into sliding contact with the solar panel in a repeatingpattern. The sliding contact between the belt and the solar panel occursunder a pressure and relative velocity sufficient to generate a forcethat results in at least one of a cleaning, buffing, and polishing.

In accordance with a further aspect, the first and second supports eachdefine substantially cylindrical members.

In accordance with a still further aspect, the first and second supportseach has a rigidity in excess of the rigidity of the belt.

In accordance with another aspect, a surface treatment tool configuredto perform at least one of a cleaning, buffing, and polishing action ona solar panel surface is provided. The tool includes a backer plate anda pad. The pad is comprised of closed-cell silicone foam rubber and thepad is attached to the backer plate. The backer plate is configured tomove such that a portion of the pad is brought into sliding contact withthe solar panel in a repeating pattern. The sliding contact between thepad and the solar panel occurs under a pressure and relative velocitysufficient to generate a force that results in at least one of acleaning, buffing, and polishing.

In accordance with a further aspect, the backer plate is configured tomove in at least one a side-to-side motion, front-to-back motion,twisting motion, and orbital motion and combinations thereof.

In accordance with a still further aspect, wherein the backer plate hasa rigidity in excess of the rigidity of the pad.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows the effects on a solar panel after brushing with a brushaccording to an embodiment of the present invention;

FIG. 1B shows the effects on a solar panel after brushing with a brushaccording to an embodiment of the present invention;

FIG. 1C shows the effects on glass after brushing with a brush accordingto an embodiment of the present invention;

FIG. 2 shows a cross-section view of an elongated structural member withC-channel grooves, having brush flaps according to a first arrangement;

FIG. 3A shows a cross-section view of an elongated structural memberwith C-channel grooves, having a brush flap according to a secondarrangement;

FIG. 3B shows a cross-section view of an elongated structural memberwith C-channel grooves, having a brush flap and flexible memberaccording to a another arrangement;

FIG. 3C is a perspective view of the coil-shaped element threadedthrough a material in accordance with at least one embodiment of thepresent invention;

FIG. 4A is a side view of the coil-shaped element according to onearrangement prior to insertion into the groove of a c-channel;

FIG. 4B is a side view of the coil-shaped element according to a furtherarrangement prior to insertion into the groove of a c-channel;

FIG. 5A is a side view of the biased coil-shaped element of FIG. 4Aprior to insertion into the groove of a c-channel;

FIG. 5B is a side view of the biased coil-shaped element of FIG. 4Bprior to insertion into the groove of a c-channel;

FIG. 6A is a side view of the coil-shaped element of FIG. 4A afterinsertion into the groove of a c-channel;

FIG. 6B is a side view of the coil-shaped element of FIG. 4B afterinsertion into the groove of a c-channel;

FIG. 7A is a front view of the coil-shaped element of FIG. 4A afterinsertion into the groove of a c-channel;

FIG. 7B is a front view of the coil-shaped element of FIG. 4B afterinsertion into the groove of a c-channel;

FIG. 8 is a front view of the coil-shaped element being removed from thegroove of a c-channel in accordance with at least one embodiment of thepresent invention;

FIG. 9 shows a cross-section and perspective view of a surface treatmenttool having two supports and a belt extending therebetween; and

FIG. 10 shows an elevation view of a surface treatment tool having abacker and a pad.

DETAILED DESCRIPTION CERTAIN OF EMBODIMENTS OF THE INVENTION

By way of overview and introduction, the invention is described inconnection with one or more embodiments in which a silicone foammaterial is provided to perform one of a cleaning, buffing, andpolishing of a surface. The silicone foam material can be supported by acore member that can be a C-channel extrusion to provide a rotatablebrush. The silicone foam brush can be used in various cleaningapplications, but it has been found to provide significant benefitsduring dry cleaning of solar panels, as discussed in more detail below.The silicone foam material is a closed-cell silicone foam. The siliconefoam can be provided in the form of sheets. The thickness and dimensionsof the foam sheets are selected based upon design requirements of thecleaning objectives. For example, thicker sheet material can be providedwhere increased brush force is required.

The use of a closed-cell silicone foam rubber material providessignificant improvements over standard brush designs and materials. Itwas found that use of closed-cell silicone foam as a brush materialprovides a lubricating effect during cleaning operations. Reducingfriction between the brush and the cleaning surface is important toreduce wear on the brush materials as well as wear on the cleaningsurface. Again, it is particularly important to prevent wear on thecleaning surface when the surface being cleaned is a solar panel sincedamage to the glass surface/anti-reflective coating of solar panels cansignificantly impact performance of the solar panels over time. In theparticular application of dry cleaning solar panel surfaces, it has beenobserved that the silicone material itself appears to provide alubricating effect between the brush and the cleaning surface. Thislubricating effect reduces wear and damage to both the brush materialand the cleaning surface.

Typically, water and/or soap are used during the cleaning of solar panelsurfaces. However, due to the lubricating effect of the closed-cellsilicone rubber, the solar panels can be cleaned dry, without the use ofsoap and/or water. Using closed-cell silicone foam rubber, whichprovides a lubricating effect, significantly reduces the time, cost, andenvironmental impact of cleaning solar panels versus using soap andwater. The infrastructure associated with providing the water to thesolar panels (which may be located in remote, arid regions), theapplication of the water and soap to the panels, and the cost and effortof environmentally disposing of the waste water and soap can be avoided.Accordingly, using the silicone foam rubber without requiring water, andalso without requiring soap can provide significant advantages in termsof performance, cost, efficiency, and environmental impact.

In addition to its lubricating effect, closed-cell silicone foam rubberalso resists the retention of moisture, dust, and debris into thestructure of the brush material. Accordingly, the brushes resistbecoming water logged if moisture is present, which can affect theperformance of the bush due to increased and/or unbalanced weight.Resistance to dust and debris retention reduces the chance that dust anddebris will damage the cleaning surface. The closed-cell silicone rubberalso has a higher elasticity as compared to designs using typicalsynthetic foam. The higher elasticity of the closed-cell silicone foamrubber increases performance of the brush because the closed-cellsilicone foam rubber is better able to conform to the cleaning surfaceas the brush rotates, especially at high rotation speeds. The ability ofthe brush to conform to the surface increases the contact surface areabetween the brush and surface which increases cleaning efficiency.Closed-cell silicone foam rubber is also resistant to UV light and hasfavorable strength and durability characteristics. Accordingly, theclosed-cell silicone foam rubber brush of the present invention isparticularly suited for high demand applications, such as cleaning ofsolar panels exposed to harsh outdoor environments. However, thecharacteristics of the closed-cell silicone foam rubber brush aresuitable for a number of cleaning applications, including intraditional, wet-cleaning brush applications.

Closed-cell silicone foam rubber brushes provides another unexpectedbenefit in the application solar panel cleaning in that the use ofclosed-cell silicone foam rubber brushes improve the efficiency of thesolar panel to collect and convert light to electricity. According toone experiment, solar panels were exposed to 20 years equivalent ofdaily cleaning of solar panels exposed to sand with various brushmaterial. The performance of the solar panels was tested prior tobushing, after bushing, and then were measured again after a washingwith water. The surface of the panels was also imaged with a scanningelectron microscope to detect surface wear. The results of the testingare shown in FIG. 1A.

Referring to FIG. 1A, the solar panel surface wear due to the variousbrushing with nylon, cloth, and closed-cell silicone foam rubber(“rubber”) can be seen in the microscope images. The surface brushedwith a nylon brush has deep, parallel scratching of the non-reflectivecoating. The cloth brush wore the anti-reflective coating sosignificantly that it left holes in places. The silicone rubber foambrush (“rubber”) left marks in a cross-hatch pattern, but they were notvery deep as compared to the nylon brush and cloth brush.

The panels were also tested using a solar cell testing setup thatmeasures the solar cell's electrical current production under standardlight/temperature conditions. Electrical current production isproportional to the amount of light that the cells are receiving(through the glass/coating/dirt). This is a standard method ofdetermining the performance of a cleaning solution, surface coating, orcell composition. The cells were each measured originally, prior tobushing, with the result are shown in the chart of FIG. 1A shown ascolumn “a” (at least 2 independent cells, measured multiple times). Thecells were cycled through the wear test and performance was measuredagain (column “b”). Then the panels were washed with water and measuredagain (column “c”).

For the cells that were cleaned with the nylon brush, the cell'sperformance remained constant throughout the procedure. Though theanti-reflective coating experienced significant wear, it was notsufficient to change the performance of the cell in standard conditionsby a significant amount.

For the cells that were cleaned with the (non-woven) cloth brush,performance dropped after the wear test. However, performance was nearlyrestored to levels prior to the wear test after washing with water,despite the damage to the anti-reflective coating.

In the case of the silicone rubber foam brush, a clear rise inefficiency of the cell was observed, as shown by columns b and c of thegraph. After brushing and washing, the solar cells brushed with theclosed-cell silicone foam rubber brush produced more than 1.02Normalized Open Circuit Current. Moreover, referring to FIGS. 1B and 1C,data indicates improvements in solar panel performance and glasstransmissivity, respectively. Although the reason for this improvementis not conclusively understood, it is believed that it is due to thenon-linear roughening of the surface at the microscopic level caused bythe brushing with the closed-cell silicone foam rubber. The surfaceroughening may break up the uniformity of the surface and let more lightthrough. This improvement in the performance of the solar panelindicates that cleaning with the silicone rubber foam brush is not onlyadvantageous for the purpose of cleaning, but solar panel performancemay also benefit from pre-deployment treatments by brushing withclosed-cell silicone foam rubber. Accordingly, it may be useful toexpose a solar panel surface to brushing with a closed-cell siliconerubber foam brush in simulated cleaning cycles until an improvement inefficiency of the solar cell is achieved. As one example, it may bebeneficial to expose the solar panel surface to approximately 7,000cleaning cycles in which the brush removes sand from the surface of thepanels.

Referring to FIG. 2, a closed-cell silicone foam rubber brush 1000 isshown according to one embodiment. The brush 1000 includes an extrusion1002 having a cross-section that provides structure for the mechanicalattachment of accessories. The extrusion 1002 includes C-channel grooves1020 around its perimeter. The C-channels further comprise a mouth 1026and two opposing lips 1022A and 1022B attached to either side of themouth. A sheet of closed-cell silicone foam rubber material 200 isattached to the extrusion 1002 such that the sheet is secured in two,adjacent C-channel grooves to form two brush flaps 2002 and 2004 thatextend from the extrusion. The free ends 2002 and 2004 of the sheet 2000each define a flap of the brush. The intermediate portion 2006 of thesheet 2000 is secured to the extrusion 1002. A first section 2008 of theintermediate portion 2006 is inserted in a first C-channel 1020. Asecond section 2010 of the intermediate portion 2006 is inserted in asecond C-channel 1020. A third section 2012 of the intermediate portion2006 extends around a section of the outer periphery of the extrusion1002 between the two C-channels. Attachment rods 2050 and 2052 aredisposed within each of the C-channels and are positioned such that thesheet material is disposed between the extrusion 1000 and the attachmentrods 2050 and 2052. The attachment rods 2050 and 2052 secure the foamsheet in place. Accordingly, attaching two foam sheets to the extrusion1002 in this manner results in a brush having four flaps. As anotherexample, the extrusion can include more or less C-channels in order toprovide a core member that has more or less attachment points for thesheets of material. Accordingly, the core member can include a varyingnumber of flaps disposed around its periphery, and more specifically, anouter periphery, and extending therefrom. The flaps can be arranged inpairs such that they are disposed on opposite sides of the core member.In other arrangements, the flaps can be spaced about the outer peripheryof the core member at equal spacings in order to provide a balanceddistribution about the core member. During cleaning, buffing, orpolishing operations, the free ends portions and/or a more proximalsection of the flap can contact the surface depending on the velocity,rigidity (bending), and/or spacing of the flaps from the surface.Accordingly, a portion of the flap is brought into sliding contact withthe surface to perform a cleaning, buffing, or polishing operation.

Referring to FIG. 3A, a closed-cell silicone foam rubber brush 3000 isshown according to one embodiment. The brush 3000 includes an extrusion3002 having a cross-section that provides structure for the mechanicalattachment of accessories. The extrusion 3002 includes C-channel grooves3020 around its perimeter. The C-channels further comprise a mouth 3026and two opposing lips 3022A and 3022B attached to either side of themouth. A sheet of closed-cell silicone foam rubber material 4000 isattached to the extrusion 3002 at each C-channel. The sheet is folded tocreate a double-side flap 4002. The middle area 4004 of the flap 4002can include a filler material (e.g., a second expanded foam) thatprovides mechanical support to the silicone foam rubber flap. The fillermaterial, which provides a flexible, structural support, can be selectedin order to achieve a desired mass, stiffness, inertia, and contactprofile of the brush flaps based on the characteristics of the fillermaterial.

As another example, referring to FIG. 3B, in addition to the fillermaterial or as an alternative to the filler material a piece of springsteel 4005 can be included to provide additional rigidity. The springsteel can increase the pressure applied to the surface during brushingsuch that the pressure is sufficient to perform the cleaning, buffing,and/or polishing operation on the surface. In the arrangement shown inFIG. 3B, the spring steel 4005 is disposed on the inner side of thefolded sheet while the outer side is available to slidingly contact thesurface. In this structural arrangement, the spring steel is adjacent atrailing side of the flap material irrespective of the direction ofmovement of the flap since the leading side (i.e., the side thatcontacts the surface) is on an outer side of the folded flap. In otherarrangements (e.g., a non-folded flap arrangement of FIG. 4A-4B), theflexible structural element (e.g., spring steel, filler backing, othersufficiently stiff member, etc.) can be located adjacent the trailingside (i.e., non-contracting side) of the flap. The flexible structuralelement can extend along the entire width of the flap and also have asimilar height as the flap. In other arrangements, the flexiblestructural element can have a width less than the flap width and/or canhave a height less than the flap height.

As shown in FIGS. 3A and B, the extrusions include four C-channels. Asanother example, the extrusion can include more or less C-channels inorder to provide a core member that has more or less attachment pointsfor the sheets of material. Accordingly, the core member can include avarying number of flaps disposed around its periphery, and morespecifically, an outer periphery, and extending therefrom. The flaps canbe arranged in pairs such that they are disposed on opposite sides ofthe core member. In other arrangements, the flaps can be spaced aboutthe outer periphery of the core member at equal spacings in order toprovide a balanced distribution about the core member.

Other structures that can be used to secure the silicone foam rubbermaterial (e.g., silicone foam rubber material sheet 4000) that forms thecleaning surface of a brush are disclosed in co-pending U.S. patentapplication Ser. No. 15/425,441, filed Feb. 6, 2017 and titled“Tool-Less Spring Attachment to C-Channel and Method of Using Same,”which is hereby incorporated by reference as if set forth in itsentirety herein. In one embodiment, the coil-shaped element 100 isconnected to the silicone foam rubber material 104 that is to beattached or detached to the c-channel. The coil-shaped element can bemade from a variety of materials that are sufficiently durable andresiliently compressible in response to an applied force. In certainembodiments, the coil-shaped element is a steel spring or a plasticspring. In other embodiments, the coil-shaped element has a coating oris made from a softer/flexible material to avoid having a sharp edge ateach coil element along the pitch of the coil.

In a particular embodiment, as shown in FIG. 3C, at least one relativelythin sheet of silicone foam rubber material 104 is connected to thecoil-shaped element 100. In certain constructions, the silicone foamrubber material can be used without any connection adapters or adhesivesbecause the coil-shaped element 100 can be directly threaded through thesilicone foam rubber material 104. One type of connector or adapter maybe an additional layer or extension of material that is sewn orotherwise attached to the silicone foam rubber material 104 that is tobe connected. The coil-shaped element is then connected to theadditional layer or extension. In one embodiment, the coil-shapedelement is connected only to the additional layer or extension. Such aconfiguration may be useful for certain applications in which it is notdesirable to pierce the silicone foam rubber material with thecoil-shaped element. In another embodiment, the coil-shaped element isconnected to both the additional layer or extension and the siliconefoam rubber material 104 itself. In one embodiment, holes 103 arepunctured in the silicone foam rubber material 104 so that thecoil-shaped element 100 can be threaded through the silicone foam rubbermaterial 104. In another embodiment, the coil-shaped element 100 has apiercing tip with a compressive strength selected to be sufficient topuncture a thin material without permanently deforming its coiled shape,including the segment of the coil-shaped element that is just proximalto the piercing tip. The coil-shaped element 100 can be threaded throughthe material by feeding end 102 through the holes 103 in the siliconefoam rubber material 104. In another embodiment, an adhesive is used toattach the silicone foam rubber material 104 to the coil-shaped element100 so that the stress is distributed over a larger area, rather thanjust at the contact points of the coil-shaped element 100 and thesilicone foam rubber material 104. As discussed in more detail below, asealant can further be used to distribute stress over a larger area andreinforce the connection of the coil-shaped element 100 and siliconefoam rubber material 104. Other methods of connecting the coil-shapedelement to the silicone foam rubber material can be used.

In other embodiments, the coil-shaped element is used to mount sensorsor to route cables along or within the grooves of equipment built usingaluminum extrusions, such as c-channels.

In another aspect of the invention, the coil-shaped element 100, 110 hasa native, unbiased shape, as shown in FIGS. 2A and 2B. The interior ofthe c-channel groove 215 is formed by walls 210, 211, and 212. Itfurther has an interior dimension from wall 210 to 211, and an aperturewith a dimension that is less than the interior dimension from wall 210to 211. In some embodiments, as shown in FIG. 2A, the coil-shapedelement 100 has a dimension that is the same size as or wider than theaperture 201 of the c-channel 200, but less than the width of theinterior of the c-channel groove (from wall 210 to 211). This enablesthe coil-shaped element 100 to be navigated through the aperture 201 andrest within the c-channel groove 215 without falling out of theaperture. Such a configuration may be used when the coil-shaped element100 is the same as or close to the length of the c-channel 200, suchthat the coil-shaped element 100 will not slide out of place. If thecoil-shaped element only covers parts of the c-channel groove, it isimportant to secure the coil-shaped element so that it does not slidealong the groove. Some uses of the coil-shaped element 100 and siliconefoam rubber material 104 may create a secure connection between thecoil-shaped element 100 and the groove 215. A spinning rotation of thec-channel, for example, may create a centrifugal force that holds thecoil-shaped element 100 and silicone foam rubber material 104 in place.In other embodiments, as shown in FIG. 2B, the coil-shaped element 110has a dimension that is wider than both the aperture 201 and theinterior of the c-channel groove (from wall 210 to 211). This enablesthe coil-shaped element to be frictionally seated against the innerwalls 210, 211, 212 of the groove 215, which inhibits or impedes releaseof the coil-shaped element from the channel and sliding therein.Inserting the coil-shaped element orthogonally can also impede orprevent sliding.

A salient aspect of the invention is that the invention enablesattachment-to and detachment-from the c-channel groove without requiringtools and without needing to access the end of the c-channel. Therefore,the silicone foam rubber material 104, or the sensors or cables and soon, need not be slid into the groove from the end of the c-channel.Having the ability to attach or detach the material from anywhere alongthe length of the groove is particularly advantageous in systems whereonly a portion of the c-channel may be accessible. Inserting thematerial along the length of the groove instead of at the end alsoeliminates the need for tools to be used to disassemble and reassemblethe system. The coil-shaped element can span the entire length of thec-channel groove or a portion of it such that the silicone foam rubbermaterial 104 is only supported at certain places.

In use, a coil-shaped element is connected to the desired silicone foamrubber material 104, which can be achieved by threading or adhesive,among other means. As discussed above, the dimension of the coil-shapedelement in its unbiased state is greater than the dimension of theaperture 201 of the c-channel groove. In some embodiments, a coating isapplied to the coil-shaped element prior to connection to avoid ithaving a sharp or rough edge. In other embodiments, as discussed in moredetail below, reinforcement can be added to the silicone foam rubbermaterial 104 before or after it is connected to the coil-shaped elementto prevent ripping. The coil-shaped element is then attached or mountedto the c-channel groove by twisting (and thereby advancing into thechannel) or squeezing the coil-shaped element into a biased state. Theapplication of another force can be used to get the coil-shaped elementinto a biased state, such as a manually applied force. The biased stateresults from resilient compression of the coil-shaped element along itslength, not by compressing it end to end, as shown in FIGS. 5A and 5B.Enough force must be applied to bias the coil-shaped element to adimension that is less than or equal to the dimension of the aperture201. FIG. 5A shows biased coil-shaped element 100′, which is biased tothe point where it can be navigated through the aperture 201 of thegroove 215. The biased coil-shaped element 100′ is then positioned suchthat at least a portion of it is in the c-channel groove 215, as shownin FIG. 4A. The biased coil-shaped element 100′ can then be restored toits original dimension, which is less than the dimension of the interiorof the c-channel groove 215 but greater than the dimension of theaperture 201.

In another embodiment, as shown in FIG. 5B, the biased coil-shapedelement 110′ must be biased to the point where it can be navigatedthrough the aperture 201 of the groove 215. That is, it must be biasedto a dimension that is less than or equal to the dimension of theaperture 201. The biased coil-shaped element 110′ is then positionedsuch that at least a portion of it is in the c-channel groove 215, asshown in FIG. 4B. The biased coil-shaped element 110′ can then berestored so that it approaches its original dimension, which is largerthan both the aperture and the interior of the c-channel groove. Thebiased coil-shaped element 110′ will expand until it is frictionallyseated against at least one of the interior walls 210, 211, 212 of thec-channel groove. Depending on the size of the c-channel groove 215 andthe coil-shaped element 110, the coil-shaped element 110 may expand toits original dimension or some dimension less.

In other embodiments, at least the coil-shaped element and top portionof the silicone foam rubber material 104 that is connected to thecoil-shaped element are sealed together. For instance, the sealant canextend along an edge or flap of the silicone foam rubber material 104.In another embodiment, if an additional layer is attached to thesilicone foam rubber material 104, the sealant can extend along an edgeor flap of that layer. Types of sealants may include silicone, acrylicresins, adhesive, epoxy, wax, polyurethane, or rubber. Methods ofsealing may include dipping, painting or spraying, and each method canresult in sealing at least a portion of the coil-shaped element andmaterial together, whether continuously along an edge or flap of thesilicone foam rubber material 104, or otherwise. The sealant serves asan extra reinforcing layer and aids in distributing any stresses along alength of the silicone foam rubber material 104 or additional layer, asthe case may be, rather than just at the points of contact between thecoil-shaped element and the material. This can further prevent or reduceripping of the material at the points of contact with the coil-shapedelement.

In some embodiments, when the silicone foam rubber material 104 isattached to the c-channel groove 200 using the coil-shaped element asshown in FIG. 7A or 7B, a cleaning brush is defined. The coil-shapedelement can be attached to the c-channel groove either in-line ororthogonally.

The coil-shaped element can be removed in a similar fashion to itsinsertion, where the coil-shaped element is biased so that it can benavigated out of the aperture 201 of the c-channel groove.

FIGS. 6A, 6B, 7A and 7B show another aspect of the invention, wherein anend portion of the coil-shaped element 101, 111 is extended outside ofthe aperture 201. The end portion 101, 111 protrudes out of thec-channel groove so that it is easily accessible and functions similarto a tab pull or as a pulling point. In use, this can be achieved bypositioning end portion 101, 111 at an angle prior to insertion orbending end portion 101, 111 after insertion so that it extends out ofthe c-channel groove. FIG. 8 demonstrates that the end portion 101 canbe pulled out of the c-channel groove, thereby removing the coil-shapedelement 100 and the silicone foam rubber material 104 attached to it.

In other embodiments, the silicone foam rubber material 104 can bereinforced against ripping at the points where the coil-shaped elementruns through the silicone foam rubber material 104 or other weak points.When polymer materials are used, such as closed-cell silicone foamsheets, the inner walls of the holes 103 can be melted to preventripping. An alternative reinforcement can comprise a glue seam (notshown) along the union of the silicone foam rubber material 104 and thecoiled-shaped element 100.

Melting of the material after connection to the coil-shaped element canhave other advantages. When the material is threaded with thecoil-shaped element, micro-tears can occur. Melting of the material canaid in mending those tears and preventing further tearing or ripping ofthe material by the coil-shaped element.

Another aspect of the invention is to use means to secure the materialto the coil-shaped element to prevent sliding or rotation around thecoil-shaped element. One way to accomplish this is by melting thematerial onto the coil-shaped element. Another way to accomplish this isby gluing the material to the coil-shaped element at points of contactbetween the material and the coil-shaped element. Depending on thematerials used, glue can be applied at some of the points of contact toachieve a secured connection. For example, a spot of glue can be appliedat one or both ends of the coil-shaped element where it meets thematerial, or only where the spring enters the material. These and allsecuring methods described herein can be applied before, during or afterthe connection of the coil-shaped element to the material, whether bythreading or otherwise.

In another aspect of the invention, the coil-shaped element is used tofacilitate the replacement of worn out flaps on a brush with new ones.In such circumstances, the coil-shaped element and/or material can bedisposable so that it does not matter if they are damaged duringremoval. When the element is removed, the material can also be removed.

In addition, the closed-cell silicone foam rubber flap material can beincorporated with or be used in combination with a cloth material (e.g.,nonwoven polyester blend cloth) to provide a hybrid brush flap.

Referring to FIG. 9, the silicone foam material can be provided in theform of a belt 500. The belt 500 can be disposed about and supported bytwo support elements 502 and 504, which can be cylindrically shapedextrusions. The supports can have a rigidity in excess of the rigidityof the belt. One or both of the support elements can be rotated in orderto move the belt to slide relative to the surface (e.g., solar panel) toperform one of a cleaning, buffing, or polishing operation on thesurface. The distance between the support elements can be adjusted inorder to adjust the tension in the belt.

Referring to FIG. 10, the silicone foam material can be provided in theform of a pad 600. The pad 600 can be supported by a backer plate 602.For example, the pad can be attached using adhesive, hook and loopfasteners, clips, etc. The backer plate can have a rigidity in excess ofthe rigidity of the pad. The backer plate 602 can be moved in aside-to-side, front-to-back, twisting, orbital, or vibrational motion ora combination thereof. The movement of the backer plate 602 can causethe pad to slide relative to a surface (e.g., solar panel) to performone of a cleaning, buffing, or polishing operation on the surface. Inaddition, the backer plate can be moved up and down relative to thesurface to adjust the pressure between the surface and the pad.

The brushes and tools described herein can be moved in various ways toperform a cleaning, brushing, or polishing operation. For example, thebrush can undergo a localized movement, which can include rotating,translating (e.g., side-to-side and/or front-to-back), twisting,orbital, or vibrational movements. The localized movement of the brushcan operate on a local area of the surface. In addition, the brush canalso undergo a macro movement relative to the surface so that largerareas of the surface can be brushed. For example, the brush can bemounted to a cleaning robot and the core member can be rotated to rotatethe flaps and the robot can move along the surface. In otherarrangements, the brush can be stationary and the surface can be movedrelative to the brush. Accordingly, various combinations of movements ofthe brushes and tools are contemplated in order to cause the siliconefoam material to slide across the surface in order to perform acleaning, brushing, or polishing operation.

The inventors have discovered, surprisingly, that the silicone foambrushes described herein provide a significant benefit when used onsolar panel surfaces, which typically include a glass. As anotherexample, the silicone foam brushes can be used on glass, which is ahard, smooth, homogenous surface, which is believed to benefit from theinvention for similar reasons as the solar panels, possibly furtherbecause of the closed-cell silicone foam rubber brush acting on asurface that comprises of a silicon-based substrate. In otherapplications, cleaning, buffing and polishing can be to hard smoothsurfaces such as industrial nails or teeth and other metal when actedupon by the brush. Car body surfaces and parts fall into this category.Stone, hard plastics and possibly rubber can be acted upon by the brushof the present invention.

While the invention has been particularly shown and described withreference to a preferred embodiment thereof, it will be understood bythose skilled in the art that various changes in form and details may bemade therein without departing from the spirit and scope of theinvention. It should be understood that various combination,alternatives and modifications of the present invention could be devisedby those skilled in the art. The present invention is intended toembrace all such alternatives, modifications and variances that fallwithin the scope of the appended claims.

1-30. (canceled)
 31. A method of performing at least one of a cleaning,buffing, and polishing action on a surface, without requiring water,comprising the steps of: providing a core member having a plurality ofC-shaped grooves; providing at least one sheet of material, the at leastone sheet of material being comprised of closed-cell silicone foamrubber and having a first free end portion, wherein the at least onesheet of material is attached to the core member with the first free endportion extending away from the core member; and causing the core memberto rotate in a first direction such that a portion of the at least onesheet of material is brought into sliding contact with the surface in arepeating pattern; wherein the at least one sheet of material includes asecond free end portion and a middle section disposed between the firstand second free end portions, and wherein at least a portion of themiddle section is attached to one of the C-channel grooves of the coremember and the first and second free end portions extend away from thecore member, and wherein the sliding contact between the at least onesheet of material and the surface occurs under a pressure and relativevelocity sufficient to generate a force that results in removal ofparticulate matter.
 32. The method of claim 31, wherein the at least onesheet of material comprises a single sheet of closed-cell silicone foamrubber.
 33. The method of claim 32, wherein the at least one sheet ofmaterials includes a plurality of free end portions arranged in asymmetrical pattern around the core member.
 34. The method of claim 31,further comprising providing a flexible structural element disposedadjacent a trailing side of the at least one sheet of material, whereinthe flexible structural element is configured to increase the pressurebetween the at least one sheet of material and the surface during thesliding contact
 35. The method of claim 31, further comprising causingthe core member to move in a second direction, wherein the seconddirection is a translational direction.
 36. The method of claim 31,wherein the surface is a solar panel and a light transmissioncharacteristic of the solar panel is improved.
 37. A method of cleaninga surface without requiring water, comprising the steps of: providing acore member having a plurality of C-channel grooves arranged in arotationally symmetric pattern; providing a plurality of sheets ofclosed-cell silicone foam rubber, each of the plurality of sheets beingfolded to form a double-sided flap; securing each of the plurality offlaps in a respective one of the plurality of C-channel grooves suchthat the flaps form a symmetric pattern around the core member; movingthe core member such that a portion of the at least one sheet ofmaterial is brought into sliding contact with the surface in a repeatingpattern; wherein the sliding contact between the at least one sheet ofmaterial and the surface occurs under a pressure and relative velocitysufficient to generate a force that results in a cleaning of thesurface.
 38. The method of claim 37, further comprising providing afiller material between the sides of the one or more of the double-sidesflaps.
 39. The method of claim 38, wherein the filler material iscomposed of an expanded foam.
 40. The method of claim 37, wherein thestep of moving the core member includes rotating the core member in afirst direction.
 41. The method of claim 40, wherein the step of movingthe core member further includes causing the core member to move in asecond direction, wherein the second direction is a translationaldirection.
 42. The method of claim 37, wherein the plurality of sheetsof closed-cell silicone foam rubber folded to form a double-sided flapare arranged symmetrically around the core member.
 43. The method ofclaim 37, wherein the surface is a solar panel and a light transmissioncharacteristic of the solar panel is improved.
 44. A method ofperforming at least one of a cleaning, buffing, and polishing action ona surface, without requiring water, comprising the steps of: providing acore member having a plurality of C-shaped grooves having an opening;providing at least one sheet of material, the at least one sheet ofmaterial being comprised of closed-cell silicone foam rubber and havinga first free end portion, wherein the at least one sheet of material isattached to the core member using a coil-shaped element, with the firstfree end portion extending away from the core member; and rotating thecore member to move in a first direction such that a portion of the atleast one sheet of material is brought into sliding contact with thesurface in a repeating pattern; wherein the sliding contact between theat least one sheet of material and the surface occurs under a pressureand relative velocity sufficient to generate a force that results in atleast one of a cleaning, buffing, and polishing.
 45. The method of claim44, wherein a dimension of the coil-shaped element in an unbiased stateis greater than a width of the openings of the C-shaped grooves, and isless than the width of the openings of the C-shaped grooves in anunbiased state.
 46. The method of claim 45, wherein the at least onesheet of material includes a plurality sheets of material, each sheethaving a free end portion.
 47. The method of claim 46, wherein the freeend portions of the plurality of sheets of material are arrangedsymmetrically around the core member.
 48. The method of claim 44,further comprising causing the core member to move in a seconddirection, wherein the second direction is a translational direction.49. The method of claim 44, wherein the coil-shaped element is attachedto the at least one sheet of material by threading.
 50. The method ofclaim 44, wherein the surface is a solar panel and a light transmissioncharacteristic of the solar panel is improved.